Disk drive head suspension tail with stiffened edge alignment features

ABSTRACT

A head gimbal assembly for a disk drive includes a flexure tail terminal region having flexure bond pads in electrical communication with the head. Each of the flexure bond pads includes a widened region of a corresponding one of a plurality of electrical traces in a conductive layer, and a discontinuous bond pad backing island in a structural layer that overlaps the widened region. The flexure tail terminal region also includes a plurality of discontinuous edge stiffener islands in the structural layer that do not overlap the widened region of any flexure bond pad, and that are disposed no more than 50 microns from one of the two opposing longitudinal outer edges of the flexure tail terminal region. At least one of the plurality of discontinuous bond pad backing islands is disposed no more than 50 microns from one of the two opposing longitudinal outer edges.

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application is a divisional of U.S. patent application Ser. No. 12/209,909, entitled “DISK DRIVE HEAD SUSPENSION TAIL WITH STIFFENED EDGE ALIGNMENT FEATURES,” filed on Mar. 13, 2014, which claims priority to provisional U.S. Patent Application Ser. No. 61/914,315, entitled “DISK DRIVE HEAD SUSPENSION TAIL ALIGNMENT FEATURE,” filed on Dec. 10, 2013, which is incorporated herein in its entirety.

BACKGROUND

Information storage devices are used to retrieve and/or store data in computers and other consumer electronics devices. A magnetic hard disk drive is an example of an information storage device that includes one or more heads that can both read and write, but other information storage devices also include heads—sometimes including heads that cannot write.

In a modern magnetic hard disk drive device, each head is a sub-component of a head gimbal assembly (HGA) that typically includes a suspension assembly with a laminated flexure to carry the electrical signals to and from the head. The HGA, in turn, is a sub-component of a head stack assembly (HSA) that typically includes a plurality of HGAs, an actuator, and a flexible printed circuit. The plurality of HGAs are attached to various arms of the actuator.

Modern laminated flexures typically include conductive copper traces that are isolated from a stainless steel structural layer by a polyimide dielectric layer. So that the signals from/to the head can reach the flexible printed circuit (FPC) on the actuator body, each suspension assembly includes a flexure tail that extends away from the head along a corresponding actuator arm and ultimately attaches to the FPC adjacent the actuator body. That is, the flexure includes traces that extend from adjacent the head and continue along the flexure tail to electrical connection points. The FPC includes conductive electrical terminals that correspond to the electrical connection points of the flexure tail.

To facilitate electrical connection of the conductive traces of the flexure tails to the conductive electrical terminals of the FPC during the HSA manufacturing process, the flexure tails must first be properly positioned relative to the FPC so that the conductive traces of the flexure tails are aligned with the conductive electrical terminals of the FPC. Then the flexure tails must be held or constrained against the conductive electrical terminals of the FPC while the aforementioned electrical connections are made, e.g., by ultrasonic bonding, solder jet bonding, solder bump reflow, or anisotropic conductive film (ACF) bonding.

An anisotropic conductive film is typically an adhesive doped with conductive beads or cylindrical particles of uniform or similar diameter. As the doped adhesive is compressed and cured, it is heated and squeezed between the surfaces to be bonded with sufficient uniform pressure that a single layer of the conductive beads makes contact with both surfaces to be bonded. In this way, the thickness of the adhesive layer between the bonded surfaces becomes approximately equal to the size of the conductive beads. The cured adhesive film may conduct electricity via the contacting beads in a direction normal to the bonded surfaces (though may not conduct electricity parallel to the bonded surfaces, since the beads may not touch each other laterally—though axially each bead is forced to contact both of the surfaces to be bonded—hence the term “anisotropic”).

In a high-volume manufacturing environment like that necessitated by the very competitive information storage device industry, there is a practical requirement for fast, cost-effective, and robust bonding of many bond pads simultaneously. Moreover, it is desirable for the bonding process to be automated, which, to be practical in a high volume manufacturing operation, would require the automated bonding equipment to be able to quickly determine and achieve proper alignment of the electrical connection points and terminals. After alignment, sufficient uniform pressure must be maintained during adhesive curing, such that a single layer of conductive beads in an ACF makes contact with both opposing surfaces to be bonded.

Accordingly, there is a need in the art for an improved HGA design that may facilitate automated rapid and reliable alignment and electrical connection of the conductive traces of a flexure tail to the conductive electrical terminals of a FPC, in the context of high volume HSA manufacture.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top perspective view of a disk drive capable of including an embodiment of the present invention.

FIG. 2 is a perspective view of a head stack assembly (HSA) capable of including an embodiment of the present invention.

FIG. 3 is a perspective view of a portion of a flexible printed circuit (FPC) according to an embodiment of the present invention.

FIG. 4A is an assembled plan view of a flexure tail terminal region, according to an embodiment of the present invention.

FIG. 4B is an exploded perspective view of the flexure tail terminal region of FIG. 4A.

FIG. 5A is an assembled plan view of a flexure tail terminal region, according to another embodiment of the present invention.

FIG. 5B is an exploded perspective view of the flexure tail terminal region of FIG. 5A.

FIG. 6A depicts a plan view of a flexure tail terminal region according to another embodiment of the present invention, facing the conductive layer side.

FIG. 6B depicts a plan view of the flexure tail terminal region of FIG. 6A, facing the structural layer side.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1 is a top perspective view of a disk drive 100 capable of including an embodiment of the present invention. The disk drive 100 includes a disk drive base 102 and two annular magnetic disks 104. The disk drive 100 further includes a spindle 106, rotatably mounted on the disk drive base 102, for rotating the disks 104. The rotation of the disks 104 establishes air flow through recirculation filter 108. In other embodiments, disk drive 100 may have only a single disk, or alternatively, more than two disks.

The disk drive 100 further includes an actuator 116 that is rotatably mounted on disk drive base 102. Voice coil motor 112 rotates the actuator 116 through a limited angular range so that at least one head gimbal assembly (HGA) 114 is desirably positioned relative to one or more tracks of information on a corresponding one of the disks 104. In the embodiment of FIG. 1, the actuator 116 includes three arms upon which four HGAs 114 are attached, each corresponding to a surface of one of the two disks 104. However in other embodiments fewer or more HGAs 114 may be included depending on the number of disks 104 that are included and whether the disk drive 100 is depopulated. Each HGA 114 includes a head 150 for reading and writing data from and to one of the disks 104. The actuator 116 may occasionally be latched at an extreme angular position within the limited angular range, by latch 120. Electrical signals to/from the HGAs 114 are carried to other drive electronics via a flexible printed circuit that includes a flex cable 122 (preferably including a preamplifier circuit) and flex cable bracket 124.

FIG. 2 is a perspective view of a head stack assembly (HSA) 200 capable of including an embodiment of the present invention. The HSA 200 includes an actuator body 232 and a plurality of actuator arms 226, 236, 238 extending from the actuator body 232. The actuator body 232 includes a pivot bearing cartridge 220 disposed in the actuator bore, and a coil support 234 that supports a coil 235 and extends from the actuator body 232 in a direction that is generally opposite the actuator arms 226, 236, 238. The HSA 200 also includes a plurality of head gimbal assemblies (HGA) 240, 242, 244, 254, attached to the actuator arms 226, 236, 238. For example, such attachment may be made by swaging. Note that the inner actuator arm 226 includes two HGAs, while each of the outer actuator arms 236, 238, includes only one HGA. This is because in a fully populated disk drive the inner arms are positioned between disk surfaces while the outer actuator arms are positioned over (or under) a single disk surface. In a depopulated disk drive, however, any of the actuator arms may have one or zero HGAs, possibly replaced by a dummy mass.

Each HGA includes a head for reading and/or writing to an adjacent disk surface (e.g. HGA 254 includes head 280). The head 280 is attached to a tongue portion 272 of a laminated flexure 270. The laminated flexure 270 is part of the HGA 254, and is attached to a load beam (the part of the HGA 254 to which the numerical label 254 points). The laminated flexure 270 may include a structural layer (e.g. stainless steel), a dielectric layer (e.g. polyimide), and a conductive layer into which traces are patterned (e.g. copper). The HSA 200 also includes a flexible printed circuit (FPC) 260 adjacent the actuator body 232. The FPC 260 includes a flex cable 262 and a preamplifier 266. The FPC 260 may comprise a laminate that includes two or more conventional dielectric and conductive layer materials (e.g. one or more polymeric materials, copper, etc.). The laminated flexure 270 includes a flexure tail 274 that runs along the actuator arm 238 to a terminal region 278 of the laminated flexure 270 that is electrically connected to bond pads of the FPC 260.

Methods of electrical connection of the flexure tails (e.g. flexure tail 274) to the FPC 260 include ultrasonic bonding of gold coatings thereon, solder reflow, solder ball jet (SBJ), and anisotropic conductive film (ACF) bonding, and are preferably but not necessarily automated. To electrically connect and securely attach the flexure tails to the FPC 260, the flexure tails are first aligned with the FPC 260, and then pressed against the FPC 260 (at least temporarily) while electrical connection is established and secure attachment is completed. Maintaining alignment and sufficient uniform pressure and temperature to groups of bond pads may be desirable during this process, and may be facilitated by certain inventive structural features in the terminal regions of the flexure tails.

FIG. 3 depicts the FPC 260 before flexure tail terminal regions (i.e. the portion of each flexure tail that overlaps the FPC, for example, flexure tail terminal region 278) are bonded thereto. The FPC 260 includes electrical conduits 382 that terminate at FPC bond pads 380, which are aligned with and connected to flexure bond pads of the terminal regions (e.g. flexure tail terminal region 278) of the HGA flexure tails. The FPC electrical conduits 382 may connect to a pre-amplifier chip 315 (shown exploded from the FPC 260 in FIG. 3). Two of the HGA flexure tails may pass through the FPC slit 310 to help facilitate their support and alignment.

The FPC 260 may include an optional insulative cover layer 320 having windows exposing the regions where the flexure tail terminal regions and the pre-amplifier chip 315 are bonded thereto. The cover layer 320 is shown cut away in the view of FIG. 3, so that the electrical conduits 382 can be better depicted.

FIG. 4A is an assembled plan view of a flexure tail terminal region 400, according to an embodiment of the present invention. FIG. 4B is an exploded perspective view of the flexure tail terminal region 400. Now referring to FIGS. 4A and 4B, the flexure tail terminal region 400 includes a structural layer 410 (e.g. stainless steel), a conductive layer 430 (e.g. copper), and a dielectric layer 420 (e.g. polyimide) between the structural layer 410 and the conductive layer 430. The flexure tail terminal region 400 may also include an optional cover layer 440 that comprises an electrically insulative material (e.g. an insulative polymer). In certain embodiments, the thickness of the structural layer may be preferably less than 20 microns, the thickness of the dielectric layer may be preferably less than 15 microns, the thickness of the conductive layer may be preferably less than 15 microns, and a total thickness at each of the plurality of flexure bond pads may be preferably at least 25 microns.

In the embodiment of FIGS. 4A and 4B, the flexure tail terminal region 400 is bounded by two opposing longitudinal outer edges 402, 404. The flexure tail terminal region 400 includes a plurality of flexure bond pads 452, 454, 456 that are aligned with corresponding ones of a plurality of FPC bond pads (e.g. FPC bond pads 380 of FIG. 3). The dielectric layer 420 may optionally include a plurality of through openings 422, for example to control the spread of ACF material used to make electrical connections to the bond pads 452, 454, 456.

In the embodiment of FIGS. 4A and 4B, the plurality of flexure bond pads 452, 454, 456 each includes a corresponding one of a plurality of widened regions 432, 434, 436 of a plurality of electrical traces 438 in the conductive layer 430, and a corresponding one of a plurality of discontinuous bond pad backing islands 412, 414, 416 in the structural layer 410. Note that each of the discontinuous bond pad backing islands 412, 414, 416 in the structural layer 410 overlaps a corresponding one of the widened regions 432, 434, 436 of the electrical traces 438 in the conductive layer 430.

In the embodiment of FIGS. 4A and 4B, the flexure tail terminal region 400 also includes a plurality of discontinuous edge stiffener islands 413, 417 in the structural layer 410 that do not overlap any of the widened regions 432, 434, 436 of any flexure bond pad 452, 454, 456. In the embodiment of FIGS. 4A and 4B, the discontinuous edge stiffener island 413 is disposed no more than 50 microns from the longitudinal outer edge 402, and the discontinuous edge stiffener island 417 is disposed no more than 50 microns from the longitudinal outer edge 404.

In the embodiment of FIGS. 4A and 4B, the bond pad backing island 412 is also disposed no more than 50 microns from the longitudinal outer edge 402, and the bond pad backing island 416 is disposed no more than 50 microns from the longitudinal outer edge 404. The structural layer islands 412, 414, 416 that pertain to the flexure tail bond pads 452, 454, 456 may also serve to transfer heat and pressure from a flat thermode tool to the plurality of bond pads 452, 454, 456 (simultaneously), for example to facilitate ACF bonding.

In the embodiment of FIGS. 4A and 4B, preferably at least 30% of the total longitudinal extent 474 of the flexure tail terminal region 400 is longitudinally spanned by the longitudinal extent 479 of the discontinuous bond pad backing island 412 and the longitudinal extent 477 of the discontinuous edge stiffener island 413. Also, in the embodiment of FIGS. 4A and 4B, preferably at least 30% of the total longitudinal extent 474 of the flexure tail terminal region 400 is longitudinally spanned by the longitudinal extent 476 of the discontinuous bond pad backing island 416 and the longitudinal extent 478 of the discontinuous edge stiffener island 417. In this context, the total longitudinal extent 474 of the flexure tail terminal region 400 is considered to be longitudinally spanned by the longitudinal extent of any structural layer island that is disposed no more than 50 microns from either of the longitudinal outer edges 402, 404.

For example, if the total longitudinal extent 474 of the flexure tail terminal region 400 were 3.5 mm, then either of the discontinuous edge stiffener islands 413, 417, together with either of the edge-adjacent discontinuous bond pad backing islands 412, 416, may preferably cumulatively span at least 1 mm of the total longitudinal extent 474 of the flexure tail terminal region 400. For example, the structural layer islands 412, 413 that reinforce the longitudinal outer edge 402 (or the structural layer islands 416, 417 that reinforce the longitudinal outer edge 404) may preferably cumulatively span at least 1 mm of the longitudinal extent of the flexure tail terminal region 400.

Likewise, if the total longitudinal extent 474 of the flexure tail terminal region 400 were 5.5 mm, then either of the discontinuous edge stiffener islands 413, 417, together with either of the edge-adjacent discontinuous bond pad backing islands 412, 416, may preferably cumulatively span at least 1.6 mm of the longitudinal extent of the flexure tail terminal region 400. For example, the structural layer islands 412, 413 that reinforce the longitudinal outer edge 402 (or the structural layer islands 416, 417 that reinforce the longitudinal outer edge 404) may preferably cumulatively span at least 1.6 mm of the longitudinal extent of the flexure tail terminal region 400.

In certain embodiments, the maximum longitudinal spacing or gap between the structural layer islands that reinforce each of the longitudinal outer edges (e.g. the gap between structural layer islands 412 and 413, or the gap 472 between structural layer islands 416 and 417) is preferably less than 50% of the total longitudinal extent 474 of the flexure tail terminal region 400.

In certain embodiments, the dimensional limitations described in the six preceding paragraphs can strengthen or reinforce the longitudinal outer edges 402, 404, and thereby help facilitate travel of an automatic long tail (ALT) combing/alignment tool along the longitudinal outer edges 402, 404 of the flexure tail terminal region 400 to align the flexure tail terminal region 400 during the head stack assembly process. The foregoing dimensional limitations may also simplify the fixture design for a dynamic electrical testing apparatus that is used to test parts during manufacture.

Now referring to FIGS. 3, 4A and 4B, in certain embodiments the FPC 260 preferably may be designed so that the FPC conductive traces 382 are not disposed in locations that would overlap with the discontinuous edge stiffener islands 413, 417 (i.e. the islands in the structural layer 410 that reinforce the longitudinal outer edges 402, 404 of the flexure tail terminal region 400, but that are not coincident with flexure tail bond pads 452, 454, 456). Otherwise, such locations may be subject to undesirably high pressure from a thermode tool during the process of bonding the flexure tail terminal region 400 to the FPC 260, which may undesirably reduce the pressure or uniformity of pressure applied to the bond pads 452, 454, 456 by the thermode tool. Likewise, FPC conductive traces 382 are preferably not disposed in locations that would overlap with any frame or peninsula that may optionally be included in the structural layer 410 of the flexure tail terminal region 400 to increase the rigidity of the longitudinal outer edges 402, 404 (e.g. to facilitate alignment during bonding steps of the head stack assembly process).

FIG. 5A is an assembled plan view of a flexure tail terminal region 500, according to an embodiment of the present invention. FIG. 5B is an exploded perspective view of the flexure tail terminal region 500. Now referring to FIGS. 5A and 5B, the flexure tail terminal region 500 includes a structural layer 510 (e.g. stainless steel), a conductive layer 530 (e.g. copper), and a dielectric layer 520 (e.g. polyimide) between the structural layer 510 and the conductive layer 530. The flexure tail terminal region 500 may also include an optional cover layer 540 that comprises an electrically insulative material (e.g. an insulative polymer). In certain embodiments, the thickness of the structural layer may be preferably less than 20 microns, the thickness of the dielectric layer may be preferably less than 15 microns, the thickness of the conductive layer may be preferably less than 15 microns, and a total thickness at each of the plurality of flexure bond pads may be preferably at least 25 microns.

In the embodiment of FIGS. 5A and 5B, the flexure tail terminal region 500 is bounded by two opposing longitudinal outer edges 502, 504. The flexure tail terminal region 500 includes a plurality of flexure bond pads 552, 554 that are aligned with corresponding ones of a plurality of FPC bond pads (e.g. FPC bond pads 380 of FIG. 3). The dielectric layer 520 may optionally include a plurality of through openings 522, for example to control the spread of ACF material used to make electrical connections to the bond pads 552, 554.

In the embodiment of FIGS. 5A and 5B, the plurality of flexure bond pads 552, 554 each includes a corresponding one of a plurality of widened regions 532, 534 of a plurality of electrical traces 538 in the conductive layer 530, and a corresponding one of a plurality of discontinuous bond pad backing islands 512, 514 in the structural layer 510. Note that each of the discontinuous bond pad backing islands 512, 514 in the structural layer 510 overlaps a corresponding one of the widened regions 532, 534 of the electrical traces 538 in the conductive layer 530.

In the embodiment of FIGS. 5A and 5B, the flexure tail terminal region 500 also includes a plurality of discontinuous edge stiffener islands 513, 517 in the structural layer 510 that do not overlap any of the widened regions 532, 534 of any flexure bond pad 552, 554. In the embodiment of FIGS. 5A and 5B, the discontinuous edge stiffener islands 513, 517 are each disposed no more than 50 microns from the longitudinal outer edge 502.

In the embodiment of FIGS. 5A and 5B, the bond pad backing islands 512 are each disposed no more than 50 microns from the longitudinal outer edge 504. The structural layer islands 512, 514 that pertain to the flexure tail bond pads 552, 554 may also serve to transfer heat and pressure from a flat thermode tool to the plurality of bond pads 552, 554 (simultaneously), for example to facilitate ACF bonding during head stack assembly.

In the embodiment of FIGS. 5A and 5B, preferably at least 30% of a total longitudinal extent of the flexure tail terminal region 500 is longitudinally spanned by at least one of the discontinuous bond pad backing islands 512 and the discontinuous edge stiffener island 513. Also, in the embodiment of FIGS. 5A and 5B, preferably at least 30% of a total longitudinal extent of the flexure tail terminal region 500 is longitudinally spanned by at least one of the discontinuous bond pad backing islands 512 and the discontinuous edge stiffener island 517. In this context, the total longitudinal extent of the flexure tail terminal region 500 is considered to be longitudinally spanned by the longitudinal extent of any structural layer island that is disposed no more than 50 microns from either of the two longitudinal outer edges 502, 504.

For example, if the total longitudinal extent of the flexure tail terminal region 500 were 3.5 mm, then either of the discontinuous edge stiffener islands 513, 517, together with at least one of the edge-adjacent discontinuous bond pad backing islands 512 may preferably cumulatively span at least 1 mm of the total longitudinal extent of the flexure tail terminal region 500. Likewise, if the total longitudinal extent of the flexure tail terminal region 500 were 5.5 mm, then either of the discontinuous edge stiffener islands 513, 517, together with at least one of the edge-adjacent discontinuous bond pad backing islands 512 may preferably cumulatively span at least 1.6 mm of the total longitudinal extent of the flexure tail terminal region 500.

In certain embodiments, the maximum longitudinal spacing or gap between the structural layer islands that reinforce each of the longitudinal outer edges (e.g. between any adjacent two of the structural layer islands 512, or between the structural layer islands 513 and 517) is preferably less than 50% of the total longitudinal extent of the flexure tail terminal region 500.

In certain embodiments, the dimensional limitations described in the five preceding paragraphs can strengthen or reinforce the longitudinal outer edges 502, 504, and thereby help facilitate travel of an automatic long tail (ALT) combing/alignment tool along the longitudinal outer edges 502, 504 of the flexure tail terminal region 500 to align the flexure tail terminal region 500 during the head stack assembly process. The foregoing dimensional limitations may also simplify the fixture design for a dynamic electrical testing apparatus that is used to test parts during manufacture.

Now referring to FIGS. 3, 5A and 5B, in certain embodiments the FPC 260 preferably may be designed so that the FPC conductive traces 382 are not disposed in locations that would overlap with the discontinuous edge stiffener islands 513, 517 (i.e. the islands in the structural layer 510 that reinforce the longitudinal outer edge 502 of the flexure tail terminal region 500, but that are not coincident with flexure tail bond pads 552, 554). Otherwise, such locations may be subject to undesirably high pressure from a thermode tool during the process of bonding the flexure tail terminal region 500 to the FPC 260, which may undesirably reduce the pressure or uniformity of pressure applied to the bond pads 552, 554 by the thermode tool during the head stack assembly process.

FIG. 6A depicts a plan view of a flexure tail terminal region 600 according to another embodiment of the present invention, facing the side that includes its conductive layer 630. FIG. 6B depicts a plan view of the flexure tail terminal region 600, facing the side that includes its structural layer 610. Now referring to FIGS. 6A and 6B, the flexure tail terminal region 600 includes a structural layer 610 (e.g. stainless steel), a conductive layer 630 (e.g. copper), and a dielectric layer 620 (e.g. polyimide) between the structural layer 610 and the conductive layer 630. The flexure tail terminal region 600 may also include an optional cover layer 640 that comprises an electrically insulative material (e.g. an insulative polymer).

In the embodiment of FIGS. 6A and 6B, the flexure tail terminal region 600 is bounded by two opposing longitudinal outer edges 680, 690. The flexure tail terminal region 600 includes a plurality of flexure bond pads that are aligned with corresponding ones of a plurality of FPC bond pads (e.g. FPC bond pads 380 of FIG. 3). The dielectric layer 620 may optionally include a plurality of through openings 622, for example to control the spread of ACF material used to make electrical connections to the bond pads. In the embodiment of FIGS. 6A and 6B, a ground pad 636 of the conductive layer 630 may be electrically connected to the structural layer 610 of the flexure thru a conventional via in the dielectric layer 620 (e.g. polyimide layer) that is disposed between the conductive layer 630 and the structural layer 610.

In the embodiment of FIGS. 6A and 6B, the plurality of flexure bond pads each includes a corresponding one of a plurality of widened regions 632, 634 of a plurality of electrical traces 638 in the conductive layer 630, and a corresponding one of a plurality of discontinuous bond pad backing islands 612, 614 in the structural layer 610. Note that each of the discontinuous bond pad backing islands 612, 614 in the structural layer 610 overlaps a corresponding one of the widened regions 632, 634 of the electrical traces 638 in the conductive layer 630. In the embodiment of FIGS. 6A and 6B, each of the bond pad backing islands 612 is disposed no more than 50 microns from the longitudinal outer edge 690, although that is not true for the bond pad backing islands 614. The structural layer islands 612, 614 that pertain to the flexure tail bond pads may also serve to transfer heat and pressure from a flat thermode tool to the plurality of bond pads (simultaneously), for example to facilitate ACF bonding.

In the embodiment of FIGS. 6A and 6B, the flexure tail terminal region 600 also includes a plurality of discontinuous edge stiffener islands 613, 615 in the structural layer 610 that do not overlap any of the widened regions 632, 634 of any flexure bond pad. In the embodiment of FIGS. 6A and 6B, the discontinuous edge stiffener island 613 is disposed no more than 50 microns from the longitudinal outer edge 680, and the discontinuous edge stiffener islands 615 are each disposed no more than 50 microns from the longitudinal outer edge 690.

In the embodiment of FIGS. 6A and 6B, the flexure tail terminal region 600 further comprises narrow peninsulas 617, 619 in the structural layer 610 that are contiguous with the structural layer 610 in the flexure tail as it runs outside of the flexure tail terminal region (e.g. contiguous with the structural layer that runs along the actuator arm in 238 in flexure tail 274 of FIG. 2). In the embodiment of FIG. 6B, the narrow peninsula 617 is disposed no more than 50 microns from the longitudinal outer edge 680, and the narrow peninsula 619 is disposed no more than 50 microns from the longitudinal outer edge 690. In this context, a peninsula is narrow if it is more than three times longer than it is wide in the plan view of FIG. 6B.

In the embodiment of FIGS. 6A and 6B, preferably at least 30% of the total longitudinal extent 674 of the flexure tail terminal region 600 is longitudinally spanned by the discontinuous bond pad backing islands 612 and the discontinuous edge stiffener islands 615. Also, in the embodiment of FIGS. 6A and 6B, preferably at least 30% of the total longitudinal extent 674 of the flexure tail terminal region 600 is longitudinally spanned by at least one of the discontinuous bond pad backing islands 612 and the discontinuous edge stiffener island 613. In this context, the total longitudinal extent 674 of the flexure tail terminal region 600 is considered to be longitudinally spanned by the longitudinal extent of any structural layer island that is disposed no more than 50 microns from either of the longitudinal outer edges 680, 690.

In certain embodiments, the maximum longitudinal spacing or gap between the structural layer reinforcements of each of the longitudinal outer edges (e.g. any gap between adjacent structural layer islands 612 and 615, or the gap 672 between structural layer island 613 and narrow peninsula 617) is preferably less than 50% of the total longitudinal extent 674 of the flexure tail terminal region 600.

In certain embodiments, the dimensional limitations described in the five preceding paragraphs can strengthen or reinforce the longitudinal outer edges 680, 690, and thereby help facilitate travel of an automatic long tail (ALT) combing/alignment tool along the longitudinal outer edges 680, 690 of the flexure tail terminal region 600, to align the flexure bond pads with corresponding ones of the FPC bond pads. The alignment may be accomplished by contact (along a longitudinal contact span) between the alignment tool and at least one of the longitudinal outer edges 680, 690. In the embodiment of FIG. 6B, the longitudinal spacing 672, or the maximum longitudinal spacing between any adjacent edge-reinforcing structural layer islands 612, 615, may be preferably no greater than 50% of the longitudinal contact span. In certain embodiments, such dimensional inequality may help facilitate more reliable alignment of the flexure tail and the FPC during the head stack assembly process.

Now referring to FIGS. 3, 6A and 6B, in certain embodiments the FPC 260 preferably may be designed so that the FPC conductive traces 382 are not disposed in locations that would overlap with the discontinuous edge stiffener island 613 or the narrow peninsulas 617, 619. Otherwise, such locations may be subject to undesirably high pressure from a thermode tool during the process of bonding the flexure tail terminal region 600 to the FPC 260, which may undesirably reduce the pressure or uniformity of pressure applied to the flexure bond pads by the thermode tool during head stack assembly.

In the foregoing specification, the invention is described with reference to specific exemplary embodiments, but those skilled in the art will recognize that the invention is not limited to those. It is contemplated that various features and aspects of the invention may be used individually or jointly and possibly in a different environment or application. The specification and drawings are, accordingly, to be regarded as illustrative and exemplary rather than restrictive. For example, the word “preferably,” and the phrase “preferably but not necessarily,” are used synonymously herein to consistently include the meaning of “not necessarily” or optionally. “Comprising,” “including,” and “having,” are intended to be open-ended terms. 

What is claimed is:
 1. A method of assembling a head stack assembly for a disk drive, the method comprising: providing an actuator including at least one actuator arm and a flexible printed circuit (FPC) that includes a plurality of electrically conductive FPC bond pads; attaching at least one head gimbal assembly to the at least one actuator arm, the at least one head gimbal assembly comprising a head for reading and writing data; and a suspension assembly that comprises a load beam, and a laminated flexure that comprises a structural layer, a conductive layer, and a dielectric layer between the structural layer and the conductive layer, the laminated flexure including a tongue portion that connects to the head and a flexure tail; positioning the flexure tail so that a terminal region of the flexure tail overlaps the FPC, the flexure tail terminal region being bounded by an outer edge, the flexure tail terminal region including a plurality of flexure bond pads in electrical communication with the head, each of the plurality of flexure bond pads including a widened region of a corresponding one of a plurality of electrical traces in the conductive layer; and one of a plurality of discontinuous bond pad backing islands in the structural layer that overlaps the widened region; wherein the flexure tail terminal region also includes a plurality of discontinuous edge stiffener islands in the structural layer that do not overlap the widened region of any flexure bond pad; and wherein each of the plurality of discontinuous edge stiffener islands is disposed no more than 50 microns from the outer edge; and contacting the outer edge with an alignment tool within 50 microns of at least one of the discontinuous edge stiffener islands.
 2. The method of claim 1 further comprising contacting the outer edge with the alignment tool over a longitudinal contact span that is at least twice a maximum longitudinal spacing between the at least one of the plurality of discontinuous bond pad backing islands and an adjacent one of the plurality of discontinuous edge stiffener islands.
 3. The method of claim 1 further comprising bonding each of the plurality of flexure bond pads to the corresponding one of the plurality of FPC bond pads by an anisotropic conductive film.
 4. The method of claim 1 wherein the FPC includes a FPC patterned conductive layer that includes the electrically conductive FPC bond pads, and further comprising aligning the flexure tail terminal region so that the FPC patterned conductive layer does not overlap any of the plurality of discontinuous edge stiffener islands of the flexure tail terminal region.
 5. The method of claim 1 wherein contacting the outer edge with the alignment tool comprises causing the alignment tool to travel along the outer edge over a longitudinal contact span. 